Fuel level always showing full? MEP-802a Fuel level sending unit replacement.

[Chrispyny]

A couple months ago i noticed my fuel level on the guage was stuck at full even though the tank was almost empty. I went through the threads here and found the directions to the testing procedure for the guage. Then i decided, i’m way to lazy for that, and decided to make an educated decision and throw parts at it.

After all the threads and THIS VIDEO i found on youtube,

https://m.youtube.com/watch?v=ZDwyqbAoGcM

I decided that more than likely, the fuel level sending unit was the culprit.

I used the video to order all the parts. They arrived last night and i replaced the part this morning. Fuel guage is now correct. Problem solved.

The part was almost $64 delivered via amazon prime. It can probably be had for $10 less if you shop around and wait several days for shipping but i’m on vacation this week and decided it was getting done NOW.

I also purchased an aux fuel sending unit as well but i’m waiting on the gasket which i hope to be here before sunday. The aux fuel unit came but doesn’t come with a gasket.

In hind sight, i wish i had held off on the aux fuel sending unit as it was almost $49 shipped off ebay and at this point i feel it isn’t malfunctioning. Since my 802 is a 2001 unit purchased a couple years ago by me from govplanet with 22hours, i figure the aux sending unit is 17 years old and may as well be replaced for peace of mind.

The above youtube author also has a video on how to replace the aux fuel level sender. Both are great vids.

Just wanted to post this for others with a similar issue, as it seems to arrise often.

 

[justacitizen]

very good! Thank You. i need to do this to my 802A

 

[Chrispyny]

I should add that these replacement parts are stainless steel, and FAR superior to the oem parts. The floats are also made from different material which lasts way longer. Good for anyone whos mep’s are older. If you plan on, or have your genset apart, these parts are kinda almost cheap enough to just replace for insurance.

 

[Guyfang]

Still, if it ain't broke, don't fix it. Just because the part is 17 years old is no reason to change it. If you start like that, then you might as well just replace the whole thing.

 

[Bmxenbrett]

Your lazy but your going to throw a sending unit at it and not just get your meter out?

My gauge was doing the same thing. I took 15min and tested it, the sender was good. Ordered a stewart werner gauge for $42 and took another 15min to put it in and attach the gauge back lighting. That was a few years ago, my sender is still good.

 

[paine]

Any idea if the Autometer 3262 is the same float type as in the video? When I search for it it appears that it is the normal float on the end of a rod type of sender.

Also would the same gauge work for an 803a or is the tank different?

Thanks.

 

[Guyfang]

Any part that will fit an 802 fuel tank, will fit an 803 fuel tank. Look in the TM.

 

[paine]

Any part that will fit an 802 fuel tank, will fit an 803 fuel tank. Look in the TM.

I am lazy and for some reason I thought I remembered the 803 had a larger tank.

Thanks for your help!

 

[Light in the Dark]

The 803 does have a larger tank, but I think to Guy's point... same top termination on both tanks so both accessory sets will fit (though not technically be correct, like the floats wont be at the same levels).

 

[paine]

The 803 does have a larger tank, but I think to Guy's point... same top termination on both tanks so both accessory sets will fit (though not technically be correct, like the floats wont be at the same levels).

Exactly why I asked the question. I know the OE sender float design is adjustable. The new sending unit design shown in the video provided would appear to be not adjustable. I am going to remove and attempt to adjust my current sending unit float, if that fails I liked the design on the new part shown in the video. I guess it will take more looking on my end to find a part for the 803.

Thanks to Guy and his wealth of information on these machines, and I am sure answering questions that the infamous TM clearly provides gets old but this issue being that there is an option for a new designed part would be a valid question for maybe someone on the forum that may have already felt with it.

Thanks !

 

[Light in the Dark]

I don't have the specs handy, but I recall using a generic float assy from Summit or similar, and just modifying the arm to work with the tank in an 803.

 

[Guyfang]

You are right!

I should have looked in the book!.

 

[paine]

So does anyone know if there is a updated sending unit for the 803a ?

 

[Ray70]

Your best bet is to ditch the float arm sending unit and use the Stainless Marine type units discussed above. It bolts right in and works perfectly.
The 802 takes a 5.5" long unit and the 803 needs an 8.5" However, if you do a little research here you will find several other posts about these sending units, in one of them I mention that on an 803 when using the 8.5" sender, there is a possibility of the float touching the side of the tank drop-off wall if the top of your plastic tank is warped at all. Adding a plastic spacer at the bottom of the sender that is slightly larger diameter than the float will eliminate any potential problems.

 

[paine]

Your best bet is to ditch the float arm sending unit and use the Stainless Marine type units discussed above. It bolts right in and works perfectly.
The 802 takes a 5.5" long unit and the 803 needs an 8.5" However, if you do a little research here you will find several other posts about these sending units, in one of them I mention that on an 803 when using the 8.5" sender, there is a possibility of the float touching the side of the tank drop-off wall if the top of your plastic tank is warped at all. Adding a plastic spacer at the bottom of the sender that is slightly larger diameter than the float will eliminate any potential problems.

Thanks, exactly the previous experience I was hoping to find. Now to search out the needed part.